Don Honorio Ventura Technological State University

Bacolor (Main) Campus

College of Engineering and Architecture
Department of Mechanical Engineering

Combined Cycle
Powerplant
(Natural Gas Fired)

Joshua B. Colis Mr.Ariel Mallari

BSME 5-C ME LAB
 I. Introduction

Combined cycle is a characteristics’ of a power

producing engine or plant that employs more than one
thermodynamic cycle. Heat engine are only able to use a
portion of the energy of their generation usually less than
50%. The remaining heat from combustion is generally
wasted.

Combining two or more cycle such as Brayton cycle

and Rankine cycle results in improved overall efficiency. In a
combined cycle power plant (CCPP) or combined cycle
gas turbine (CCGT) plant, as gas turbine generator
generates electricity and waste heat is used to make steam
to generate additional electricity via a steam turbine, this
last step enhances the efficiency of electricity generation.

As a rule, in order to achieve high efficiency, the

temperature difference between the input and output heat
levels be as high as possible. This is achieved by combined
the Brayton (gas) and Rankine (steam) thermodynamics
cycle.
 II. Definition
In electric power generation a combined cycle power
plant is an assembly of heat engines that work in tandem
from the same source of heat, converting it into mechanical
energy, which in turn usually drives electrical generators. The
principle is that after completing its cycle (in the first
engine), the
temperature of
the working fluid
in the system is
still high enough
that a second
subsequent heat
engine extracts
energy from the
heat that the first
engine
produced. By combining these multiple streams of work
upon a single mechanical shaft turning an electric
generator, the overall net efficiency of the system may be
increased by 50–60%. That is, from an overall efficiency of
say 34% (simple cycle), to possibly an overall efficiency of
62% (combined cycle), 84% Theoretical efficiency (Carnot
cycle). This can be done because heat engines are only
able to use a portion of the energy their fuel generates
(usually less than 50%). In an ordinary (non-combined cycle)
heat engine the remaining heat (i.e., hot exhaust gas) from
combustion is wasted.
 III. History - America
In 1960, North America claimed its piece of the pie
when a power plant in Port Mann, British Columbia became
the largest gas plant in the world, operating with a 100 MW
capacity. A year later in 1961, the first combined-cycle
plant began operation in Korneuburg, Austria. It generated
75 MW of electricity.

Since that time, generative capacities have grown

exponentially, and technologies have evolved dramatically.
Today's combined-cycle plants operate with greater
efficiencies and lower emissions than any other type of fossil
plant, and it's realistic to expect these numbers to continue
to evolve and improve. Natural gas plants supply more than
half the energy consumed in residential and commercial
applications, and 41 percent of the energy used by U.S.
industries, all while producing half the carbon dioxide, a
third the nitrogen oxides, and one percent the sulfur oxides
of the average coal-fired plant.
Cape Canaveral Clean Energy Center in America

Duke Energy Florida, America

 IV. History - Philippines
One of the Combined Cycle Powerplants in the
Philippines is Ilijan Combined-Cycle Power Plant. Ilijan
Combined-Cycle Power Plant is a dual-fuel power station in
Ilijan, Batangas City. It is primarily a natural gas plant and
uses distillate oil as a secondary back-up fuel source. With
the nameplate capacity of 1200 MW, it is the largest natural
gas facility in the Philippines. The plant is designed to draw
natural gas from the Malampaya gas field.[2]

The plant is the first power facility in the country to use

the 500 kV switchyard system and reverse osmosis system.[2]
The Ilijan plant's construction began in March 1999 and was
commissioned in June 2000.
 V. History – World Development
The four sets of generation!

1. First Generation Combined Cycle

2. Second Generation Combined Cycle
3. Third Generation Combined Cycle
4. Fourth Generation Combined Cycle

The commercial development of combined-cycle

systems has proceeded in parallel with gas turbine
development.

We are presently in the third generation technology of

combined-cycle systems and are at the launch point of the
fourth generation.
 1. First Generation
The first gas turbine installed in an electric utility in the United
States was applied in a combined cycle. This was a 3.5 MW
gas turbine that used the energy from the exhaust gas to
heat feedwater for a 35 MW conventional steam unit.

The gas turbine is shown in the figure below. A schematic

showing the
combined-cycle
system is shown in
figure in the next
page. This system
entered service in
June

1949, and a
similar system was
added to this
station in 1952. The heat recovery economizers applied in
these systems used bare tubes, as was typical of heat
exchangers in combined-cycle systems installed prior to
1959.

Most combined-cycle power generation systems installed

during the 1950s and early 1960s included conventional-
fired boilers. These systems were basically adaptations of
conventional steam plants with the gas turbine exhaust gas
serving as combustion air for the boiler. The efficiency of this
type of combined cycle was approximately 5–6% higher
than that of a similar conventional steam plant. These
systems could economically utilize bare tubes in the boiler
because of the high mean temperature difference
between the combustion products and the water/steam.

The repowering of steam power plants with gas turbine

generators and HRSGs is still attractivein many applications
today as evidenced by the recent Colorado Public Service,
Fort St. Vrain installation, which was placed in commercial
operation in 1999.
 2. Second Generation
Equipment that made it economically feasible to weld
continuous spiral fins to tubes was introduced to boiler
manufacturers in 1958. Heat recovery combined cycles,
using the sensible heat in the gas turbine exhaust gas, were
made feasible by the enhanced gas-side heat transfer using
finned tubes. Combined-cycle systems with finned tube
boilers entered service in 1959.

During the 1960s the application of the heat recovery

type of combined-cycle systems became more prevalent.
Its initial application was in power and heat applications
where its power-to-heat ratio was more favorable. Also, a
small number of the heat recovery type combined cycles
were installed in utility power generation applications during
the 1960s.

Application of these systems in the 1970s and 1980s

established the heat recovery feedwater heating
combined-cycle as a mature technology for baseload and
mid-range service.
 3. Third Generation
The first and second generations combined cycles were
configured using gas turbine designs that were optimized for
simple-cycle output and efficiency. Gas turbine design
optimization for simple-cycle and for combined cycle
output and thermal efficiency is illustrated.

Specific power (i.e., output per pound of airflow) is

important since the higher the value, the smaller the gas
turbine required for design power output. The importance of
thermal efficiency is obvious since it directly impacts the
operating fuel cost. Figure 8 illustrates a number of
significant points.

1. Where simple-cycle efficiency is the goal, high pressure

ratio is desirable.

2. Where combined-cycle efficiency is the objective,

more modest pressure ratios are selected.

3. Firing temperature has a greater impact on combined-

cycle efficiency than simple-cycle efficiency. Fuel price
escalation in the 1970s and 1980s further increased the
need for more efficient power plants for base- and mid-
range service. This led to gas turbine designs in the late
1980s that were optimized specifically for combinedcycle
efficiency.
 4. Fourth Generation
Further gas turbine materials development and hot gas
path cooling technology advances, as well as higher
temperature and pressure steam cycles, will continue the
trend for more efficient combined-cycle systems in the
future.

Gas turbines installed in the first, second and third

generation combined-cycle plants are configured with
open-loop cooling of the turbine hot gas path and cooling
air supplied from the compressor. Hot gas path components
are in large part cooled by film cooling. As a result, there is
significant exhaust gas temperature drop across the first
stage nozzle, and significant “chargeable air” required to
cool down the steam turbine stages. The drop in exhaust
gas temperature across the first stage nozzle and the
increase in chargeable cooling loss due to increases in
turbine firing temperature may diminish efficiency gains to
the point of being uneconomical.
 VI. Components of Combine Cycle Powerplant
The overall purpose of a combined cycle plant is to
provide electricity for consumer use. The gas turbine
produces electricity and hot exhaust; the heat recovery
steam generator transfers the heat from this hot exhaust to
water in order to
make superheated
steam. The
superheated steam
produced in the
heat recovery
steam generator is
supplied to the
steam turbine
through steam
piping. The steam is
then used by the
steam turbine to
make electricity,
and the exhaust
steam is then cooled and condensed back into water in the
condenser.
 1. Gas Turbine

The gas turbine uses natural gas or various other fuels,

such as No. 2 diesel or kerosene, and compressed air to
produce a force to turn the gas turbine rotor that is
connected to a generator. The resultant hot exhaust gases
from the outlet of the gas turbine are then directed to a
heat recovery steam generator to recover the heat before
being exhausted to atmosphere.
 2. HRSG
The heat recovery steam generator, or HRSG, which is
commonly spoken as “hersig,” removes heat from the hot
exhaust of the gas turbine to turn water into superheated
steam. This is done by directing the hot exhaust across
finned tubes filled with water. This water absorbs the heat
and turns into saturated steam. The steam rises up to the
drum, and the moisture in the saturated steam is removed
by mechanical separators; it is then sent through piping to
another set of finned tubes to superheat it. This superheated
steam is sent to
the steam
turbine. The hot
exhaust from
the gas turbine
exits the
“hersig” through
an exhaust
stack to
atmosphere.
 3. Steam Turbine
The steam turbine receives superheated steam from the
“hersig” in order to turn the steam turbine rotor, which is
connected to a generator to make electricity. The
superheated steam is directed to the steam turbine from
the “hersig” by steam piping. After the superheated steam is
used to operate the steam turbine, it is exhausted into the
condenser.
 4. Balance of Plant
The balance of plant is comprised of the condenser,
condensate, and feed systems. The purpose of the
condenser is to receive steam that has been exhausted
from the steam turbine and condense it back to water. This
is performed by running cooling water through tubes in the
condenser, which absorbs heat from the exhausted steam
in order to turn it back to water. This water is then pumped
from the condenser to the low-pressure steam drum by the
condensate pumps. The feed pumps take suction from the
low-pressure steam drum to provide water for the high-
pressure and intermediate-pressure steam drums.
 VII. Process
This is how a combined-cycle plant works to produce
electricity and captures waste heat from the gas turbine to
increase efficiency and electrical output.
 1. Gas turbine burns fuel.

The gas turbine compresses air and mixes it with fuel that
is heated to a very high temperature. The hot air-fuel
mixture moves through the gas turbine blades, making them
spin.

The fast-spinning turbine drives a generator that converts

a portion of the spinning energy into electricity.
 2. Heat recovery system captures exhaust.

A Heat Recovery Steam Generator (HRSG) captures

exhaust heat from the gas turbine that would otherwise
escape through the exhaust stack.

The HRSG creates steam from the gas turbine exhaust

heat and delivers it to the steam turbine.
 3. Steam turbine delivers additional electricity.

The steam turbine sends its energy to the generator drive

shaft, where it is converted into additional electricity.
 VIII. Advantages
Combined cycle plant has great advantages as:

 It’s highly reliable, flexible and available.

 The size and weight are small enough to be suitable for

ships, aircraft engines, and locomotives gas turbines.

 We can use natural gas, which is a very suitable fuel.

 The lower initial cost compared to an equivalent steam

plant.

 The cooling water required is less than for steam plant

of the same capacity output.

 It can start_up and shut_down quickly with less start_up

losses.

 Maintenance and installation time is less compared to

a thermal power plant.
 We can locate these plants near to load centers so
transmission cost and losses reduced.

 This plant can run off any fuel like oil, gas, biogas, or
methane gas.

 The high overall efficiency exceeding 50% and low

emission levels of pollutants make it suitable for use in
heavily populated regions.

 It’s generally operated fully automatically so it’s

suitable for use where operating staff is less
experienced.

 It’s easy to convert simple gas turbine units to

combined cycle operational power plant using gasified
coal and replacing the turbine burners to accomplish
the fuel conversion.
 IX. Disadvantages
There are some disadvantages of the combined power
plant as:

 The technologies needed are more expensive and

complex, so initial investments for building a plant is
high.

 The Maintenance cost is high.

 It isn’t suitable as a peak load plant.

 The natural gas used is a non_renewable and a highly

flammable source.

 The efficiency of part load demand is poor.

 It requires special metals to maintain the unit operated

at high temperature and pressure.
 X. Applications
After whole we know about this plant we wouldn’t inquire
to know that it’s used in over 4400 facilities including:

 Industry: as chemical plants, sawmills, refineries,

laundries, food industry, plastic molding industry,
farming, and greenhouses because combined plants
provide a stable electrical power supply which we
can isolate them from the local electricity grid in
needing.

 Hospitals: we all know that hospitals need high

electrical and thermal energy for the critical reliability
so they use a 2 MW combined plant to enhance the
quality of power by assuring smooth operation of the
clinical devices.

 Commercial: as office buildings, airports, shopping

malls, hotels, health clubs, universities and so on
where they need to reduce the size and the capital
investment in production equipment.

 Institutions: like prisons, military bases, schools.

 Manufacturers: as chemical, refining, ethanol, pulp

and paper, and glass manufacturing.
 XI. Issues Involving CCPP

The challenge

A combined cycle power plant customer was having

issues with severe erosion at the elbow of their reheat
interstage attemperation loop due to increased cycling at
the plant. This caused the plant to perform extensive repairs
costing millions of dollars. The attemperators are located in
heat recovery steam generators (HRSG) between the
primary and secondary superheaters on the reheat (RH)
lines, requiring accurate temperature control across a wide
range of operations from startup to full-load of steam
turbine.
The solution

The IMI CCI team worked closely with the customer to

define the true operating cases based on distributed control
system (DCS) data from all four units, including: startup, shut
down, normal operation, and transition between units.
These actual process conditions allowed the team of Valve
Doctors® to evaluate the cooling water spray atomisation
based on the kinetic energy, degree of superheat, and the
pipe velocity. The team concluded the limiting factor to be
the insufficient distance to the downstream bend for the
installed probe style desuperheaters.

Based on the request from the customer’s corporate

office, the IMI CCI team and the customer’s nominated
consultant collaborated to provide a detailed report of the
root cause analysis and recommended solution. The solution
included changing probe style desuperheaters to ring style
desuperheaters and increasing the downstream distances
to ensure sufficient water droplet evaporation. The following
features of the DAM-B ring style desuperheaters enable
superior steam temperature control:

A flow profiling liner is welded to the inside of the DAM

body to increase steam velocity, achieve better secondary
atomisation.
 The nozzles receive water from a common spray water
pipe encircling the steam pipe, supplying water evenly
across the nozzles.

Nozzle design prevents flashing inside the nozzle and

maintains a certain water atomisation pressure at any flow
condition to achieve superior primary atomisation.

The 100DSV spraywater valve, using DRAG® disk stack

technology, was supplied separate from the attemperator,
so that the internal controlling elements are not subject to
the thermal stresses of an integrated water valve-probe
design. The final solution was delivered to the customer in
eight weeks to meet the plants outage/installation
requirements. A month later, the customer extended the
outage and requested an additional two units to be
upgraded with the IMI CCI solution.
 XII. Model Powerplant

The Ilijan Combined-Cycle Power Plant — located in

Ilijan, Batangas — is the largest natural gas facility in the
country comprising 1200 MW combined-cycle, dual-fuel
electricity generation facilities with a design life of 25 years.
Natural gas is the cleanest of all fossil fuels--synchronized
with the Philippine government's efforts in promoting
sustainable and ecologically-sound economic
development through the delivery of clean power.

The plant is principally designed to operate as a base-

load unit using natural gas from the Malampaya gas fields in
Palawan, with diesel as back-up — promoting an
ecologically sound operating environment. Integrated plant
controls based on the ABB Bailey distributed digital control
system enable plant operators to run the plant safely and
effectively.

KEPCO bagged the Build-Operate-Transfer (BOT)

contract for the construction of the Ilijan plant after fierce
competition against seven international independent
power producers (IPPs). It established KEPCO Ilijan
Corporation (KEILCO)— a consortium composed of pillars in
the energy business: KEPCO, Mitsubishi Corporation (Japan),
TeaM Energy Corporation - Tokyo Electric (Japan) &
Marubeni (Japan) and Kyushu Electric (Japan) — to
implement the BOT Project on September 12, 1997.

In February 2014, KEPCO Ilijan Corporation (KEILCO)

was named as one of the top ten industries to have shown
exemplary environmental performance during the Philippine
Environment Partnership Program (PEPP) awarding
ceremonies by the Department of Environment and Natural
Resources (DENR). This is the second time the company
received such award, the first was last October 2011.
KEILCO was cited for its environmental programs, such as
Balik Baterya, Green Procurement, Pawikan Conservation,
and for being active in coastal cleanup and tree planting
activities. KEILCO was also named as the Environmental
Company of the Year in the 2009 Asian Power Awards, and
in 2013 received the prestigious Excellence in Ecology and
Economy (E3) Award from the Philippine Chamber of
Commerce and Industry (PCCI).

The Safety Organization of the Philippines, Inc., granted

KEPCO Ilijan Corporation an Award of Honor, last November
7, 2016, in recognition of its achievement in attaining
3,395,532.00 Safe Man-Hours continuously without Lost Time
Accident (LTA) since March 2005 to August 2016

Maintains and operates the 1,200 MW natural gas-fired

combined-cycle power plant in Ilijan, Batangas. TeaM
Energy owns a 20% stake in the Ilijan Power Plant.

Ilijan Combined-Cycle Power Plant is a dual-fuel power

station in Ilijan, Batangas City. It is primarily a natural gas
plant and uses distillate oil as a secondary back-up fuel
source. With the nameplate capacity of 1200 MW, it is the
largest natural gas facility in the Philippines. The plant is
designed to draw natural gas from the Malampaya gas
field.
 The plant is the first power facility in the country to use
the 500 kV switchyard system and reverse osmosis system.
The Ilijan plant's construction began in March 1999 and was
commissioned in June 2000.
Model Plant Specifications:

Emission and Discharge Data:

 References
https://en.wikipedia.org/wiki/Combined_cycle_power_plant

http://www.oel-group.com/otsicc001.html

https://en.wikipedia.org/wiki/List_of_power_plants_in_the_Philippines

https://www.power-eng.com/articles/print/volume-119/issue-
2/departments/gas-generation/a-short-history-of-the-evolving-uses-of-natural-
gas.html

https://en.wikipedia.org/wiki/Ilijan_Combined-Cycle_Power_Plant

https://physics.oregonstate.edu/~hetheriw/energy/topics/doc/elec/natgas/cc/
combined%20cycle%20development%20evolution%20and%20future%20GER420
6.pdf

https://www.techtransfer.com/blog/combined-cycle-overview/

https://www.top-ee.com/combined-cycle-power-plant/

https://www.ge.com/power/gas/gas-turbines

http://www.imi-critical.com/case-studies/Pages/Solving-erosion-issues-at-
CCPP.aspx

http://kepcophilippines.com/ilijan-combined-cycle-power-plant

https://www.teamenergy.ph/our-business/ilijan-power-station/